Polyester

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Introduction
Polyester are polymers made by a condensation reaction taking place
between small molecules, in which the linkage of the molecules occurs
through the formation of ester groups.
Polyesters are commonly made by interaction of a dibasic acid with a
dihydric alcohol:
HOOC-X-COOH + HO-Y-OH ...OC-X-COO-Y-OCO-X-COO-Y-OCO...
The formation of polyester was studied by Wallace H. Carothers of du Point
during the investigation of polyesters which lead eventually to the discovery
of nylon. Development of the polyesters was overshadowed, however, by the
polyamide research, and it was not until 1941 that a valuable polyester fibre
was discovered. in that year, J. T. Dickson and J. R. Winfield of the Calico
Printers' Association England made a synthetic fibre from polyethylene
terephthalate by condensing ethylene glycol with terepthalic acid.
After the war, development of the fibre was carried out under license by
I.C.I. Ltd. in the UK and du du Pont in USA, resulting in the fibres known
respectively as 'Terylene' and 'Dacron'.
Today, polythylene terepthalate fibres are being made in many countries,
and modified forms of this fibre are also produced. Other polyesters have
become of commercial importance.
What is polyester?
According to Federal Trade Commission, a manufactured fibre in which the
fiber-forming substance is any long chain synthetic polymer composed of at
least 85 per cent by weight of an ester of an substituted aromatic carboxylic
acid, including but not restricted to substituted terepthalate unites p(-R-OCO-C6H4-CO-O-) and para-substituted hydroxybenzoate unites p(-R-O-C6H4CO-O-).
Types of Polyester Fibre
Polyester fibres are subdivided into the following types,
i. Polyethylene Terepthalate Fibre (PET Polyester Fibres)
ii. Poly-1, 4-Cyclohexylene-Dimethylene Terepthalate Fibres
iii. Other types of Polyester Fibre.
Among them Polyethylene Terepthalate Fibre (PET Polyester Fibres) is
mostly produced and used in daily life. So, we are discussing on it.
Polyethylene Terepthalate Fibres (PET Polyester Fibres) are produced

as multifilament yarn, staple fibre and tow, in a wide range of counts and
staple lengths to suit virtually all textile requirements.
Types and Sizes
The fibres are available in bright, semi-dull and dull lustres. The properties
of the fibre may be modified over a range which is limited by the inherent
characteristics of the polymer, each manufacturer controlling his process to
produce fibres that will meet specific requirements. In general, commercial
PET polyester fibres fall into two main classes,
a. Regular tenacity
b. High tenacity.
PET polyester fibres are produced commonly in round cross-section, but
fibres of special cross-section are now available from a number of
manufacturers.
PET polyester fibres are thermoplastic, and lend themselves well to
physical modification associated with this property. Crimped and textured
yarns of all familiar types are available.
Production
Polyethylene terephthalate is made by the condensation of terephthalic
acid, or a derivative such as dimethyl terephthalate, with ethylene glycol.

a. Ethylene Glycol: It is made by the catalytic oxidation of ethylene, which

is obtained from petroleum craching. Ethylene oxide is produced 1. Hydration
of this yields ethylene glycol2.
b. Terephthalic Acid; Dimethyl Terephthalate: Para-xylene obtained
from petroleum is oxidized3, for example with nitric acid or with air in the
presence of catalyst.
Terephthalic acid is esterified with methyl alcohol4 to form dimethyl
terephthalate.

Polymerization: Polyethylene terephthalate is made by condensing

ethylene glycol with either terephthalic acid itself or with dimethyl
terephthalate.
Condensation of ethylene glycol with terephthalic acid1 is an esterification
reaction, water being eliminated as the reaction takes place. Condensation of
ethylene glycol with dimethyl terephthalate2 is an ester interchange reaction,
methyl alcohol being eliminated as the reaction takes place. The polymer
obtained in this way would be expected to have ester end group instead of
the carboxilic acid end group in the case of the polymer obtained by the
terephthalic acid route.
In either case, the condensation is carried out by heating the ethylene
glycol and terephthalic acid or dimethyl terephthalete and removing the
water or the methyl alcohol in vacuo. When the desired degree of
polymerization has been reached, the clear, colourless polyester is extruded
through a slot on to a casting wheel. The polymer solidifies into an endless
ribbon, which is fed to a cutter and cut into chips in the form of cubes with 36mm sides.

Spinning
Polyethylene terepthalate melts at about 2600C, and the molten polymer is
stable so long as oxygen is rigorously excluded. Every care is taken during
melt spinning, as in the polymerization process, to prevent air coming into
contact with the molten polymer.
In the spinning building, the chips of polymer are dried to remove traces of
moisture, and then passed to strong hoppers. From the hoppers the chips are
fed as required to the spinning machines.
The molten polymer being pumped through holes in a spinneret. As the
filaments emerge, they solidify and are wound into packages of undrawn
yarn.

The undrawn yarn is stretched to about five times its original length on
draw-twist machines, the stretching being carried out usually at elevated
temperature. If high tenacity yarn is being made, the filaments are drawn to
higher degree than in the manufacture of regular tenacity yarn.
It is normal practice for PET polyester yarns to be drawn hot, as this gives a
more uniform product that could draw. The stretching of heavy denier yarns
and monofilaments may, however, be carried out at room temperature, as
the poor heat conductivity of the fibre makes for irregularities in thick
filaments which are drawn hot.
End Usage
PET polyester is used in different ways for its various properties. Some of
them discussed bellow;
Apparel Fabrics: PET is used alone or blended with wool, cotton, flax and
other fibres provides an extensive range of hard-wearing, comfortable,
easily-looked-after garments with high dimensional stability and wrinkle
resistance.
Curtains: The good resistance to sunlight which is a feature of PET polyester
fibres, especially behind the glass, has enable these fibres to establish an
important outlet in the curtain trade. The fast dyes used in dyeing PET
polyester fabrics have contributed generally to success in this field.
Floor Coverage: It is also used for floor coverage, notably in the production
of sliver knit rugs and tufted carpeting.
Laundry Equipment: PET polyester fibre has heat resistance property, so
for this reason PET is used as laundry equipment.
Conveyor Belt: PET polyester fibres are friction resistance, strong and soft
properties, that's why it is used for conveyor belt.
Ropes, Net, Sailcloth: PET polyester fibres can take a large amount of load
and have drape properties. For this reason it is used to produce ropes, net,
sailcloth.
Filling: PET polyester staple is used as filling in pillow, mattrace, quilts etc.

for it soft feeling property.

Sewing Thread: PET polyester fibre is used as core of core-spun yarns for
its strength and the outer layer of cotton is used. But the comfort remains
like cotton.
Electrical Insulation: PET polyester has great heat and electric resistance
power, also has the resistance to outer weather. That is why it is used for
insulation.
Tyres: PET polyester has great property of rubbing fastness and to heat. It
also remains in shape for long time. For this reason it is used as raw material
of tyres.
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